CN106714937B - Cooling dryer for compressed air and corresponding method - Google Patents
Cooling dryer for compressed air and corresponding method Download PDFInfo
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- CN106714937B CN106714937B CN201580035524.7A CN201580035524A CN106714937B CN 106714937 B CN106714937 B CN 106714937B CN 201580035524 A CN201580035524 A CN 201580035524A CN 106714937 B CN106714937 B CN 106714937B
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24F—AIR-CONDITIONING; AIR-HUMIDIFICATION; VENTILATION; USE OF AIR CURRENTS FOR SCREENING
- F24F3/00—Air-conditioning systems in which conditioned primary air is supplied from one or more central stations to distributing units in the rooms or spaces where it may receive secondary treatment; Apparatus specially designed for such systems
- F24F3/12—Air-conditioning systems in which conditioned primary air is supplied from one or more central stations to distributing units in the rooms or spaces where it may receive secondary treatment; Apparatus specially designed for such systems characterised by the treatment of the air otherwise than by heating and cooling
- F24F3/14—Air-conditioning systems in which conditioned primary air is supplied from one or more central stations to distributing units in the rooms or spaces where it may receive secondary treatment; Apparatus specially designed for such systems characterised by the treatment of the air otherwise than by heating and cooling by humidification; by dehumidification
- F24F3/1405—Air-conditioning systems in which conditioned primary air is supplied from one or more central stations to distributing units in the rooms or spaces where it may receive secondary treatment; Apparatus specially designed for such systems characterised by the treatment of the air otherwise than by heating and cooling by humidification; by dehumidification in which the humidity of the air is exclusively affected by contact with the evaporator of a closed-circuit cooling system or heat pump circuit
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/26—Drying gases or vapours
- B01D53/265—Drying gases or vapours by refrigeration (condensation)
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25D—REFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
- F25D21/00—Defrosting; Preventing frosting; Removing condensed or defrost water
- F25D21/06—Removing frost
- F25D21/12—Removing frost by hot-fluid circulating system separate from the refrigerant system
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2256/00—Main component in the product gas stream after treatment
- B01D2256/10—Nitrogen
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2256/00—Main component in the product gas stream after treatment
- B01D2256/18—Noble gases
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Abstract
The dryer for compressed air comprises at least one cooling unit (28) capable of cooling a refrigerant fluid circulating within at least one drying unit (22), having an air inlet (11) and an air outlet (13) and also comprising at least one circuit (18) in which the air to be treated circulates from the air inlet (11) to the air outlet (13). The dryer for compressed air comprises, along a circuit (18): at least one cooling device (12) configured to cool the compressed air to a positive temperature of a few degrees above zero and close to the freezing temperature; and at least one refrigerating device (14) disposed downstream of the cooling device (12) and configured to cool the compressed air to a substantially negative value.
Description
Technical Field
The present invention relates to a dryer for compressed air and a corresponding method, which can be used in applications where dehumidified compressed air must be available, for example in the pharmaceutical, food or other industries.
The invention can also be applied to drying and dehumidifying technical gases, such as but not limited to nitrogen, helium and other gases.
In particular, the moisture can be removed by gradually cooling the compressed air in order to obtain a sufficiently negative dew point temperature, which corresponds to a very high dehumidification effect.
Background
It is known that in many fields, such as the pharmaceutical and food fields, there is a need for compressed air or technical gas with a high level of quality, which is not generally obtainable by directly using a flow of ambient air that has been compressed beforehand.
It is therefore necessary to perform operations for purifying the air in order to achieve the main purpose of eliminating the humidity, so as to obtain substantially dry compressed air, i.e. compressed air almost completely free of humidity.
In general, the moisture is removed by a dehumidification operation, so as to make available a compressed air flow that is reusable according to the particular field of application.
Currently, in the field of dehumidification processes of compressed air, (which, due to conceptual and structural differences, are not comparable to systems for purifying air streams containing toxic products such as oils, dusts, percolates, etc.), different types of dryers can be used, such as adsorption-type dryers and hybrid-type dryers (i.e. a combination of the two aforementioned types), characterized by different degrees of dehumidification effect obtainable.
The cool dryer utilizes the concept of moisture condensation, which is achieved by lowering the temperature of the compressed air using a heat exchanger in a conventional cooling cycle.
One disadvantage of this type of dryer is that there is a lower operating limit of the dryer, which is related to the minimum dew point temperature achievable (which is the same as the freezing temperature).
In fact, in the temperature range close to this, there is a risk of ice formation during the condensation of the humidity and, subsequently, damage to the heat exchanger may be caused by an increase in the volume of humidity, in which the compressed air to be treated will circulate.
For this reason, cooling dryers are not used in applications requiring dried compressed air or applications having a particularly reduced moisture content, since the performance associated therewith is directly dependent on the minimum obtainable dew point temperature.
Adsorption type dryers remove moisture by using porous and hygroscopic materials (e.g., silica gel, sieves, or activated alumina) that can selectively bind to water molecules present in the compressed air.
In this way, the extraction and retention of moisture from the compressed air stream is achieved by physical and/or chemical processes without cooling, thereby avoiding the disadvantages associated with cool dryers.
One advantage of adsorption dryers relates to the high performance associated therewith, and they may even be applied in cold climates where temperatures may not be compatible with the use of cooling dryers.
Conversely, the greatest drawbacks of this type of dryer are: as they become saturated in steps, they require operations to regenerate the adsorbent material; this can be achieved, for example, by using a so-called cold regeneration technique, in which a portion of the flow of dry air, typically about 15%, is collected at the outlet.
Alternatively, according to the principle of thermal regeneration, the adsorbent material may be regenerated by using an electric resistance and a blower adapted to heat the adsorbent material and determine the evaporation of the moisture bound to the moisture absorbent material.
Both of these solutions lead to high investment and operating costs (regeneration).
Another alternative is to recover the hot flow generated during the air compression step in order to make available sufficient energy for evaporating the moisture combined with the moisture-absorbing material.
One drawback of this known solution is that it is difficult to apply in the presence of lubricated compressors, since the lubricant itself (usually oil-based) dissipates a large amount of heat, thereby reducing the total heat flow available for regeneration.
Hybrid dryers are also known, which have only recently become widespread, and which provide a first drying step in which approximately 80-85% of the moisture can be removed by cooling, followed by a further removal of the residual moisture, performed by adsorption techniques. This method allows to significantly increase the level of quality of the drying air obtainable compared to a cooling dryer, and at the same time to reduce the high operating costs associated with adsorption type dryers.
One drawback of this known solution relates to the high investment costs, since two different units are required in performing the successive dehumidification steps, and to the higher operating costs associated with the adsorption technique.
Devices for purifying compressed air are also known in the art, which use a first air cooling stage at a temperature above the freezing temperature of water, and a second cooling stage placed downstream of and in series with the first cooling stage, in which the humidity of the compressed air is frozen and then separated from the flow. Examples of such devices are described, for example, in US4,976,116 and US 5,428,963.
US 2012/0042691 is also known, which relates to a system for obtaining and recovering volatile or semi-volatile contaminants in liquid form obtained from extracted crude oil for subsequent use in non-polluting aspects. Such systems are used in particular for purifying air streams of contaminants, mainly hydrocarbons, and are used in underground or transportable fuel tanks or barrels. This document provides, in the form of an embodiment, a combined and alternative use of two circuits, wherein each circuit comprises a first cooling phase having a temperature above the freezing temperature of water and a second cooling phase having a temperature below the freezing temperature of water. As a primary purpose of this document, its teaching is for cleaning common sources containing gases and other components such as siloxanes and water from storage tanks or contaminated floors.
By means of compression and condensation, a tail gas is obtained, which may be further treated by a regenerative adsorber in order to remove residual chemical vapours, after which the tail gas may be reintroduced to the place where it is extracted.
The invention as will be described and claimed in greater detail hereinafter originates from a different field of technology, which is the field of treating compressed air by cooling in order to eliminate the water entrained in the air flow, in particular with respect to the use of said compressed air in the pharmaceutical and food fields.
In particular, it is an object of the present invention to provide a dryer for compressed air which can be operated at a sufficiently negative dew point temperature below freezing without impairing the proper operation of the dryer.
Another object of the present invention is to obtain a dryer for compressed air which operates with a cooling cycle, which can be simply achieved and which makes it possible to obtain a flow of drying air with a high level of quality, which is suitable for the most extreme applications and/or in severe climates and/or combinations thereof.
Another object of the present invention is to obtain a dryer connected to the distribution facilities of various user devices, implementing a method for drying compressed air which makes it possible to obtain at least partial energy recovery of the energy consumed during cooling by exchanging with incoming hot air and subsequently heating the dry air before it is introduced into the distribution facilities of the various user devices.
Another object of the present invention is to obtain a dryer for compressed air which can result in lower purchase costs, operating costs and energy consumption compared to both adsorption type dryers and hybrid dryers of the art.
The applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.
Disclosure of Invention
The present invention is set forth in and characterized by the following schemes 1 and 7, while the following other schemes describe other features of the invention or variations of the main inventive concept.
Scheme 1. a dryer for compressed air, the dryer comprising: an air inlet and an air outlet, two drying units and two respective circuits, within which air to be treated circulates from the air inlet to the air outlet, a first of the drying units comprising a first cooling device configured to cool the compressed air to a positive temperature of a few degrees above zero and close to freezing temperature and a first freezing device placed downstream of the first cooling device and configured to cool the compressed air to a sufficiently negative value, a second of the drying units comprising a second cooling device and a second freezing device, each of the freezing devices having a first freezing operating state and a second defrosting operating state,
it is characterized in that
-the first section of the circuit through the first cooling device and the first refrigerating device comprises at least one return section through which the air leaving the first refrigerating device flows in the opposite direction within the first cooling device and/or the second cooling device in order to cause a temperature drop of the air entering the first cooling device and/or entering the second cooling device;
-the second section of the circuit through the second cooling device and the second freezing device comprises at least one return section through which the air leaving the second freezing device flows in the opposite direction within the second cooling device and/or the first cooling device in order to cause a temperature drop of the air entering the second cooling device and/or entering the first cooling device;
-wherein the first and second sections of the circuit are connected to each other by means of a valve arrangement;
-wherein the valve means has:
at least one first operating state in which an incoming flow of compressed air is first conveyed along the first section of the circuit through the first cooling device and the first freezing device placed in its defrost state, and then conveyed along the second cooling device and the second freezing device placed in its freeze state;
and a second operating state in which the incoming flow of compressed air is first conveyed along the second section of the circuit through the second cooling device and the second refrigerating device placed in its defrost state, and then along the first cooling device and the first refrigerating device placed in its refrigerated state.
Solution 2. dryer for compressed air according to solution 1, characterized in that said first and/or said second drying unit comprises, along said circuit and downstream of the respective refrigerating apparatus, at least one deflecting element which can be selectively activated so as to choke the passage of said compressed air into one and/or the other cooling apparatus.
Solution 3. the dryer for compressed air according to solution 2, characterized in that said deflector element has a first inactive condition, in which it allows all the air streams leaving one freezer to enter the respective cooling devices of the same drying unit, a second active condition and a third active condition, so as to perform a heat exchange with the incoming air streams; in the second start-up state it diverts the entire air flow leaving one freezer into the cooling device of another drying unit; in the third starting state it is in an intermediate position so that part of the air flow leaving one freezer is diverted into the corresponding cooling device of the same drying unit and part of the air flow is diverted into the cooling device of the other drying unit.
Scheme 4. the dryer for compressed air according to any of the preceding schemes, characterized in that each of said refrigeration plants comprises two air-refrigerant exchangers arranged parallel to each other and working alternately and at least one evaporator placed downstream of said two air-refrigerant exchangers along said circuit.
Solution 5. dryer for compressed air according to any of solutions 1 to 3, characterized in that the two drying units are connected to each other in parallel and are operated alternately by means of at least one valve configured to selectively determine the passage of the compressed air into one or the other of the drying units.
Solution 6. dryer for compressed air according to solution 4, characterized in that the two drying units are connected to each other in parallel and are operated alternately by means of at least one valve configured to selectively determine the passage of the compressed air into one or the other of the drying units.
Scheme 7. a drying method for dehumidifying a compressed air stream in a dryer, said method being implemented by:
-activating the cooling unit to determine cooling of the refrigerant fluid;
-introducing said compressed air into two drying units by means of an air inlet;
wherein a first of the drying units comprises a first cooling device configured to cool the compressed air to a positive temperature of a few degrees above zero and near freezing temperature and a first freezing device disposed downstream of the first cooling device and configured to cool the compressed air to a substantially negative value, a second of the drying units comprises a second cooling device and a second freezing device, each of the freezing devices having a first freezing operating state and a second defrosting operating state,
characterized in that it provides the following further steps:
-passing the air leaving the first cooling device in the opposite direction in the first cooling device and/or the second cooling device so as to cause a temperature drop in the air entering the first cooling device and/or entering the second cooling device;
-passing the air leaving the second cooling device in the opposite direction in the second cooling device and/or the first cooling device so as to cause a temperature drop in the air entering the second cooling device and/or entering the first cooling device;
-actuating the valve means between at least a first operating condition and a second operating condition:
in the first operating state, the incoming compressed air flow is first passed through the first cooling device and the first freezing device placed in the defrost state, and then through the second cooling device and the second freezing device placed in its freeze state;
in the second operating state, the incoming compressed air flow is first passed through the second cooling device and the second freezing device placed in its defrost state, and then through the first cooling device and the first freezing device placed in its freeze state.
Scheme 8. drying method by cooling, according to scheme 7, characterized in that it provides for freezing the air alternately using at least two different air-refrigerant exchangers of the freezing apparatus, and in that, after the air is cooled and before it is frozen, the method makes the air pass through an evaporator in order to maintain the temperature at the inlet of one or the other of the air-refrigerant exchangers constant.
Solution 9. drying method by cooling according to solution 7 or 8, characterized in that defrosting of the ice formed in the freezing apparatus is achieved by causing a part of the drying air leaving the dryer to flow in the freezing apparatus by means of a cyclic or continuous activation of at least one condensation drain connected to the freezing apparatus.
In accordance with the above purposes, the present invention relates to a dryer for compressed air provided with an air inlet and an air outlet and at least one circuit in which the air to be treated circulates from the air inlet to the air outlet.
According to a possible form of embodiment, the dryer comprises, along the circuit: at least one cooling apparatus and at least one freezing apparatus, the cooling apparatus configured to cool the compressed air to a positive or negative near-freezing temperature; the refrigeration apparatus is disposed downstream of the cooling apparatus and is configured to cool the compressed air to a substantially negative value.
According to a possible form of embodiment, the cooling device comprises at least one air-air exchanger inside which flows a flow of compressed air to be dehumidified and a flow of dried compressed air, while the refrigeration device comprises at least one air-refrigerant exchanger inside which flows a flow of compressed air and a refrigerant fluid.
Advantageously, the dryer according to the invention operates at a dew point temperature that is sufficiently negative below freezing, so that a significantly greater dehumidification of the compressed air is achieved without impairing the proper functioning of the dryer itself.
According to a preferred form of implementation of the invention, the dryer comprises at least two drying units, which are sequentially connected to each other by means of at least one reversing element, which can be selectively activated to determine the passage of the compressed air in the first drying unit and then in the second drying unit.
According to another preferred form of implementation of the invention, the compressed air dryer comprises at least two drying units operating in parallel and alternately by means of at least one valve, which can be selectively activated in order to determine the passage of compressed air into one or the other of the drying units.
In this way, it is therefore possible to allow defrost regeneration operation in sections of the dryer that are not operating without loss of operating continuity.
According to a possible form of embodiment, the method for drying by refrigeration according to the invention provides: activating a cooling unit to determine cooling of the refrigerant fluid; introducing compressed air into the drying unit; cooling the compressed air in the cooling device; freezing compressed air inside at least one freezer; passing the dry compressed air through a cooling device; discharging the dry compressed air; and regenerating the refrigeration equipment.
According to a possible form of embodiment, the drying method provides: the dehumidification of the air is carried out in a cyclic manner by actuating at least one valve configured to allow the compressed air to pass alternately inside at least two different drying units, the dehumidification of the compressed air being effected inside one of said drying units and, inside the other, the regeneration being carried out by defrosting the frozen moisture and then separating and discharging the refrigerant held therein.
According to a preferred form of embodiment, the drying method provides: the dehumidification of the air is carried out in a cyclic manner by activating at least one reversing element configured to allow the passage of the air in at least two distinct drying units, the dehumidification of the compressed air being carried out in one of said drying units and the regeneration of the refrigerated humidity in the other.
Advantageously, such a drying process continuously supplies dry compressed air to the user device without interrupting the dehumidification process which performs the regeneration of the dryer itself and without incurring the costs and drawbacks of the known solutions.
Drawings
These and other features of the invention will become apparent from the following description of some forms of embodiment, which is given by way of non-limiting example with reference to the accompanying drawings, in which:
figure 1 schematically shows a dryer for compressed air in a first operating mode;
figure 2 schematically shows the dryer for compressed air of figure 1 in a second operating mode;
figure 3 schematically shows a variant of the dryer for compressed air of figure 1;
figure 4 schematically shows a dryer with circulation and continuous operation according to the invention;
figure 5 schematically shows the dryer of figure 4 in another operating mode;
figure 6 shows a variant of the dryer of figure 5;
figure 7 shows another variant of the dryer of figure 1.
To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It should be understood that elements and features of one embodiment may be readily incorporated into other embodiments without further recitation.
Detailed Description
Reference will now be made in detail to the various forms of embodiments of the invention, one or more examples of which are illustrated in the figures. Each example is provided by way of illustration of the invention and should not be construed as a limitation thereof. For example, features illustrated or described as part of one embodiment form may be used on or in conjunction with other embodiment forms to yield yet a further embodiment form. It is to be understood that the invention is intended to embrace all such modifications and variations.
In accordance with the present invention, the form of embodiment of the invention described herein relates to a dryer 10 and corresponding functionality for dehumidifying compressed air or other technical gases, such as but not limited to nitrogen, helium, and the like.
In particular, the dryer 10 can be used in a variety of applications requiring compressed air or technical gases with a reduced moisture content, such as in the pharmaceutical or food sectors, among others.
The dryer 10 may comprise at least one cooling unit 28 and a drying unit 22 that may dehumidify air, the drying unit 22 having at least one air inlet 11 and an air outlet 13, at least one circuit 18 of compressed air being definable between said air inlet 11 and said air outlet 13.
At least one cooling apparatus 12 may be disposed along a loop 18, which in the prior art operates substantially as a freeze dryer, and at least one freezing apparatus 14 is positioned in-line with the cooling apparatus 12 and configured to complete the process of removing moisture.
The cooling device 12 may also comprise at least one air-air exchanger 16, the exchanger 16 being of the type that exchanges heat directly with counter-flow or co-flow, or with cross-flow, for example.
Specifically, the air-to-air exchanger 16 may be configured to ensure removal of a majority of moisture present within the compressed air by cooling the compressed air to a positive temperature near the freezing temperature of the moisture.
The refrigeration equipment 14 may also include at least one air-refrigerant exchanger 20, such as a fin-type exchanger, configured to allow residual moisture still present in the compressed air and not retained within the air-air exchanger 16 to be refrigerated on its inner wall 21 and/or inner fins.
The cooling apparatus 12 and/or the freezing apparatus 14 may include at least one condensate separator 15 configured to separate condensed moisture from the compressed air.
Specifically, the condensation separator 15 may be, for example, a demister having a cyclone or inertial impaction.
Furthermore, in order to prevent possible drops of condensate out of the condensate separator 15, it may have a very high outlet relative to its bottom, where the condensate may accumulate.
An oil separator filter 19 may be provided along the circuit 18 and downstream of the condensate separator 15, the oil separator filter 19 being configured to separate oil present in the compressed air.
The separated moisture can then be discharged out of the dryer 10 by means of one or more condensate discharge devices 17.
The condensate separator 15 and the condensate drain 17 may be integrated to form a single device, which simultaneously may separate moisture from the compressed air and discharge the moisture out of the dryer 10.
Due to gravity and/or the presence of the partition in the lower part, the moisture can be separated directly inside the exchangers 16 and 20, by virtue of its accumulation, without the need for the condensation separator 15.
In some forms of embodiment, the dryer 10 may be cycled alternately between a freeze mode of operation (fig. 1) and a defrost mode of operation (fig. 2).
In the freezing mode of operation, compressed air generated within the unit (not shown in the figures) travels through the circuit 18 and may pass through the air-to-air exchanger 16 where it may give off heat to the dry compressed air stream.
In this way, the heat exchange may allow the temperature of the compressed air to be reduced gradually, allowing most of the moisture present to condense.
The compressed air can thus change from a high inlet temperature (e.g., about 35 ℃) to a defined dew point temperature at the outlet, which approaches a freezing temperature between about-2 ℃ to about +5 ℃, e.g., about 3 ℃.
At the outlet of the air-air exchanger 16, the moisture content of the compressed air may be reduced by about 80-90%, for example corresponding to less than 1g/Nm3Is, in particular, approximately equivalent to 0.7 g/Nm3Is incompatible with many of the above applications.
To this end, the refrigeration equipment 14 may be positioned in series with the first cooling equipment 12 and configured to further reduce the moisture content of the compressed air.
In the form of embodiment described herein, the air-refrigerant exchanger 20 can be configured so that the dew point temperature becomes negative, for example between about-40 ℃ and about-10 ℃, in particular about-20 ℃, which is equivalent to less than about 0.01g/Nm3The number of the cells.
In this way, the air-refrigerant exchanger 20 can allow the residual moisture adhering to its inner wall 21 to freeze by further cooling.
In particular, the residual moisture may be frozen, for example, by means of a refrigerant fluid, the temperature of which may be defined and adjusted by the cooling unit 28.
The cooling unit 28 may include at least one compressor 29 of refrigerant fluid, a condenser 30, a lamination control valve 31, and a lamination member 32.
The cooling unit 28 may also include a hot gas valve 33 configured to allow hot gas to be introduced into the interior of the freezer (evaporator) 14 and defrost moisture accumulated on its walls.
In some forms of embodiment of the invention, the cooling circuit may function as a thermal mass or compressor cycle with an inverter, so as to enable energy savings when there is a reduced flow of compressed air compared to the nominal capacity.
The use of the refrigerating device 14 allows to reduce the dew point temperature considerably to values that cannot be obtained with the known cooling dryers, obtaining a strong dehumidification action, while still maintaining a significant constructive simplicity and limited costs (lower than those associated with adsorption-type dryers and hybrid dryers).
Furthermore, the geometry and size of the air-refrigerant exchanger 20 may be suitably defined so as not to risk damage and blockage of the passage section due to the increased volume of refrigerated moisture.
Finally, the dry compressed air may be sent again to the air-air exchanger 16 in order to perform an initial cooling of the compressed air in order to achieve energy recovery and to reduce the humidity value of the exiting air.
This energy recovery also allows to bring the dried compressed air leaving the dryer 10 into an optimum condition compatible with the direct use in the above applications, which generally requires that the dried compressed air is at a temperature close to the ambient temperature, for example between about 20 ℃ and about 25 ℃, which is significantly greater than the temperature at the outlet of the air-refrigerant exchanger 20.
In fact, if it is not preheated, it will cause condensation of the moisture contained in the space where the compressed air is applied to the external surface of the compressed air distribution pipe.
In the form of embodiment described herein, it is possible to vary the level of dehumidification obtained, in order to increase the versatility of the dryer 10, for example by varying the operating temperature of the air in the air-refrigerant exchanger 20 electronically, mechanically or manually.
In a variant of embodiment (not shown in the figures), the refrigerating apparatus 14 can be integrated with the cooling apparatus 12 so as to obtain substantially a single compact heat exchanger, configured to obtain complete dehumidification of the compressed air.
In further variants of embodiment (also not shown in the figures), the drying unit 22 may comprise two or more freezers 14 in series, so as to vary the dehumidification effect obtainable, as required, also as a function of the user's equipment.
After the air-refrigerant exchanger 20 has been frozen to a determined amount of moisture, it must be cyclically regenerated (defrosted) in order to prevent any damage to it by subsequent work due to excessive thickness of ice.
It is therefore possible to change the operation of the dryer 10 by changing from the freezing mode of operation (fig. 1) to the defrost mode of operation (fig. 2).
Specifically, the change in the operation of the dryer 10 may be controlled by a control unit, which may detect the amount of ice formed in the air-refrigerant exchanger 20 and selectively stop the operation of the cooling unit 28.
Referring to fig. 2, in the defrost mode, high temperature compressed air (e.g., about 35 ℃) may pass through the air-to-air exchanger 16 and then through the air-to-refrigerant exchanger 20.
In this mode of operation, the cooling fluid is not introduced into the air-refrigerant exchanger 20 by the cooling unit 28 in order to prevent cooling by the compressed air and thus prevent any other ice from forming.
The compressed air can thus be gradually cooled, releasing sufficient energy to the chilled moisture to defrost.
The moisture can then be removed from the dryer 10 by the above-described condensate separator 15 and condensate drain 17 in order to restore the optimum initial conditions for operation in the freeze mode.
In this way, it is also possible to obtain compressed air to be treated at a lower temperature, reducing the energy consumption associated with its dehumidification during continuous operation in the freezing mode of operation.
In the form of some embodiments of the invention, in order to prevent the coolant flowing inside the condensate drain 17 (which is subjected to negative temperatures) from freezing, it is possible to provide an electrical type of resistance configured to heat the condensate drain 17 and prevent the formation of ice therein.
In other forms of embodiment of the invention, the air-refrigerant exchanger 20 may have dry compressed air previously obtained flowing therein or alternatively be defrosted by activating the hot gas valve 33 to inject hot gas.
In a variant of the embodiment described with reference to fig. 3, the drying unit 22 can also comprise a deflector element 23 along the circuit 18 and downstream of the freezing apparatus 14, configured so that the circuit 18 is selectively associated with the bypass circuit 35.
The deflecting element 23 can thus selectively determine that all, none or part of the air passes inside the air-air exchanger 16 after it has passed through the refrigerating device 14.
In this way, it is possible to transfer only a partial quantity of dry compressed air to the air-air exchanger 16 (for example advantageously during the freezing mode of operation) in order to keep the temperature of the air leaving the air-air exchanger 16 and entering the air-refrigerant exchanger 20 constant, at about 3 ℃.
The deflecting element 23 may be of any known type, for example a three-way valve or an electrically operated valve, the operation of which may be controlled by the control unit described above.
In a preferred form of embodiment of the invention described herein, to prevent interruption of the dehumidification process to defrost refrigerated moisture, the dryer 10 may include at least two drying units 22', 22 ".
Each drying unit 22', 22 "may have a respective cooling unit 28, in the case of fig. 4 and 5 two cooling units 28', 28".
Alternatively, it is possible to provide a single cooling unit 28 (fig. 6), which cooling unit 28 alternately delivers the cooling fluid to each of the drying units 22', 22 "by means of activating one of the lamination valves 31 according to the operating mode (freezing or defrosting) of each drying unit 22', 22".
In the embodiment forms described, for example, with reference to fig. 4 and 5, the at least two drying units 22', 22 "can be connected in series with one another by means of at least one reversing element 27 in order to reverse the travel of the compressed air, in this case two reversing elements 27', 27".
In a form of embodiment described herein, the at least one reversing element 27 may be a valve, for example a three-way or four-way valve, an electric valve or a slide valve.
In some versions of embodiments of the invention (not shown in the drawings), the four-way valve may be mounted on a single actuator to create an eight-way valve that may assume at least two positions, thereby significantly simplifying construction.
In the form of embodiment described herein, the operation of the reversing element 27 can be selectively controlled by the control unit, for example according to a predetermined duration of each cycle, for example 15 minutes of freezing and 15 minutes of defrosting for each drying unit 22' and 22 ″.
In further variants of embodiments, the reversing element 27 can be driven by monitoring at least one operating parameter of the drying units 22', 22 "with sensors and/or probes (not shown in the figures).
For example, the sensors and/or probes may be configured to detect (e.g., without limitation) the pressure drop and/or the dew point temperature of the compressed air measured at different points of the dryer 10 between the inlet and outlet of the air-refrigerant exchanger 20.
Thus, when the control unit detects that the predetermined value of the aforementioned parameter has been reached, it can then change the position of the at least one reversing element 27 and thus also the direction in which the compressed air in the drying units 22' and 22 "is directed.
Referring to fig. 4, the compressed air is delivered by the first reversing element 27 'into the first drying unit 22' in the defrost mode of operation, while the second drying unit 22 "may have a freeze mode of operation.
The hot compressed air can then pass through the first circuit 18', successively through the first cooling device 12' and the first freezing device 14 'of the first drying unit 22', progressively cooling and releasing part of its heat to the humidity that has been frozen in the previous cycle, which can then be thawed and discharged outside the dryer 10.
The compressed air can then be passed through the first cooling device 12 'again in order to be then conveyed by the reversing elements 27' and 27 "to the second drying unit 22".
The compressed air can then pass through the second cooling device 12 "and the second freezing device 14" arranged along the second circuit 18 "of the second drying unit 22" in order to obtain the desired dehumidification by using the above-described modes in a mirror-like progression to the progression in the first drying unit 22'.
When the control unit detects that the maximum allowable threshold value of at least one of the aforesaid operating parameters of the second drying unit 22 "has been exceeded, it can vary the position of the reversing elements 27' and 27" in order to reverse the aforesaid cycle (fig. 5).
In this way, the compressed air can first pass through the second drying unit 22 ″ in the defrost mode of operation and then through the first drying unit 22' in the freeze mode of operation, so as to obtain a cyclic and continuous process to dehumidify the compressed air.
According to a variant, the reversal of the first and second drying units 22', 22 "is managed by the presence of respective temperature probes (not shown), advantageously located at the cold spots of the refrigeration equipment 14', 14", which activate the reversal when a predetermined limit temperature has been reached.
In the variant shown in fig. 5, each drying unit is provided with its own deflecting element 123a, 123b, which, when selectively activated, can thus selectively determine the passage of at least a portion of the air inside the respective air-air exchanger 16 after it has passed through the respective refrigerating apparatus 14', 14 ".
In the solution shown in fig. 5, the selective actuation of the deflecting element 123b, for example, allows to divert part or all of the dehumidified airflow coming from the freezer 14 "directly into the air-air exchanger of the cooling device 12 'in the circuit 18'. The passage of the cold air flow in the air-air exchanger of the cooling device 12 "of the circuit 18" is then partially or completely bypassed.
In this case, the solution of providing the deflecting elements 123' and 123 "allows to maximize the heat exchange in the cooling device 12', in that the air directly leaving the freezing device 14" and therefore having the smallest possible temperature is conveyed to the cooling device 12', thereby increasing the cooling efficiency.
Thus, selective activation of the deflecting elements 123' and 123 "allows to position both or one of them in at least three operating positions.
In a first state or inactive state, it allows all the air streams exiting the freezing apparatuses 14', 14 "to enter the respective cooling apparatuses 12', 12" of the same drying unit 22', 22", in order to perform a heat exchange with the incoming air streams.
In a second, activated state, one or both deflecting elements 123', 123 "may divert the entire air flow leaving the freezing device 14', 14" into the cooling device 12", 12 'of the other drying unit 22', 22".
In a third, activated state, one or both deflecting elements 123', 123 "may be positioned in an intermediate position, where they divert part of the air flow leaving the freezing device 14', 14" to the respective cooling device 12', 12 "of the same drying unit 22', 22" and divert part of said air flow into the cooling device 12', 12 "of the other drying unit 22', 22".
The selective activation of the deflecting elements 123a and 123b can be timed, programmed or influenced by parameters detected during operation, for example by the delivery rate of the air flow, the temperature of the incoming flow, the heat exchange conditions, etc.
In other forms of embodiment, such as described with reference to fig. 6, the at least two drying units 22' and 22 "may be connected to each other in parallel.
In this case, the dryer 10 may comprise at least one valve 37, in the case of fig. 6 two valves 37 'and 37", configured to selectively direct compressed air into one or the other drying unit 22' and 22".
Referring to fig. 6, the compressed air may be passed to a first drying unit 22', where it may undergo dehumidification in order to undergo a subsequent temperature reduction, as described above.
Subsequently, when the amount of ice formed in the freezer 14 'will damage or destroy the device, then the first valve 37' may be deactivated, e.g. by the control unit, and at the same time the second valve 37 "may be activated.
The incoming compressed air may then be passed to the second drying unit 22", while the first drying unit 22' may undergo a defrost process according to one of the modes described above.
Although not specifically shown, the deflecting elements 123a, 123b may also be present at the outlet of the respective freezing apparatuses 14', 14 "in this case.
In a variant of the embodiment of the invention (not shown in the figures), when the compressed air present at the inlet has a delivery peak, it is possible to actuate both valves 37 'and 37 "so that the compressed air can pass simultaneously through both drying units 22' and 22" operating in the freezing operation mode, thus increasing the overall cooling capacity of the dryer 10.
In other variants of embodiment, such as described with reference to fig. 7, the refrigerating device 14 of the drying unit 22 comprises at least two air-refrigerant exchangers 20 'and 20 "arranged parallel to each other and operating alternately in a freezing mode of operation, and at least one evaporator 38, the evaporator 38 being placed downstream of the two air-refrigerant exchangers 20' and 20" and acting as a cooling circuit with a positive expansion temperature close to 0 ℃ to prevent the formation of ice.
With this configuration, it is possible to keep the temperature at the inlet of the freezing device 14 constant and approximately equal to the freezing temperature, for example approximately 2 ℃, thus avoiding varying its behavior in relation to possible temperature variations of the incoming air and making it possible to control the dryer 10 more simply.
It is clear that modifications and/or additions of parts may be made to the dryer for compressed air as described heretofore, without departing from the field and scope of the present invention.
Claims (12)
1. Dryer for compressed air, the dryer comprising: an air inlet (11) and an air outlet (13), two drying units (22 ' ) and a first (18 ') and a second circuit (18 ') within which air to be treated circulates from the air inlet (11) to the air outlet (13), a first one of the drying units (22 ') comprising a first cooling device (12 ') configured to cool the compressed air to a positive temperature of a few degrees above zero and close to freezing temperature and a first freezing device (14 ') placed downstream of the first cooling device (12 ') and configured to cool the compressed air to a sufficiently negative value, a second one of the drying units (22 ') comprising a second cooling device (12 ') and a second freezing device (14 '), each of the freezing devices (14 ' ) having a first freezing operating state and a second defrosting operating state, wherein
-the first circuit (18 ') passing through the first cooling device (12') and the first freezing device (14 ') comprises at least one return section by which the air leaving the first freezing device (14') flows in the opposite direction inside the first cooling device (12 ') and/or the second cooling device (12 ") so as to cause a temperature drop of the air entering the first cooling device (12') and/or entering the second cooling device (12");
-the second circuit (18 ") passing through the second cooling device (12") and the second freezing device (14 ") comprises at least one return section through which the air leaving the second freezing device (14") flows in the opposite direction inside the second cooling device (12 ") and/or the first cooling device (12 ') so as to cause a reduction in the temperature of the air entering the second cooling device (12") and/or entering the first cooling device (12');
-wherein said first circuit (18 ') and second circuit (18 ") are connected to each other by means of a valve arrangement (27', 27");
-wherein the valve device (27', 27 ") has:
at least one first operating condition in which an incoming flow of compressed air is first conveyed along the first circuit (18 ') through the first cooling device (12 ') and the first refrigerating device (14 ') placed in its defrosting operating condition, and then along the second cooling device (12 ") and the second refrigerating device (14") placed in its refrigerating condition;
and a second operating state in which the incoming compressed air flow is first conveyed along the second circuit (18 ") through the second cooling device (12") and the second refrigerating device (14 ") placed in its defrosting operating state and then along the first cooling device (12 ') and the first refrigerating device (14') placed in its refrigerating state,
characterized in that said first drying unit (22 ') and/or said second drying unit (22') comprise, along said first circuit (18 ') and second circuit (18') and downstream of the respective refrigeration equipment (14 '), at least one deflecting element (123 a, 123 b), said deflecting element (123 a, 123 b) being able to be selectively activated so as to choke the passage of said compressed air into one and/or the other cooling equipment (12' ),
wherein the deflecting element (123 a, 123 b) has a first inactive condition, in which it allows the entire air flow exiting one freezing device (14 ', 14 ") to enter the respective cooling device (12 ', 12") of the same drying unit (22 ', 22 ") in order to perform a heat exchange with the entering air flow, a second active condition and a third active condition; in the second start-up state it diverts the entire air flow leaving one freezing device (14 ', 14 ") into the cooling device (12", 12 ') of the other drying unit (22 ', 22 "); in the third start-up state it is in an intermediate position, so that part of the air flow leaving one freezing device (14 ', 14 ") is diverted into the corresponding cooling device (12 ', 12") of the same drying unit (22 ', 22 ") and part of the air flow is diverted into the cooling device (12", 12 ') of the other drying unit (22 ', 22 ").
2. Drier for compressed air according to claim 1, characterized in that each of said freezing devices (14 ', 14 ") comprises two air-refrigerant exchangers (20', 20") arranged parallel to each other and working alternately and at least one evaporator (38) placed downstream of said two air-refrigerant exchangers (20 ', 20 ") along said first (18') and second (18") circuits.
3. Dryer for compressed air according to claim 1 or 2, characterized in that said two drying units (22 ', 22 ") are connected to each other in parallel and are operated alternately by means of at least one valve (37; 37', 37") configured to selectively determine the passage of the compressed air into one or the other of the drying units (22 ', 22 ").
4. A drying method for dehumidifying a compressed air flow in a dryer (10), said method being implemented by:
-activating a cooling unit (28) to determine cooling of the refrigerant fluid;
-introducing said compressed air into two drying units (22', 22 ") by means of an air inlet (11);
wherein a first one of the drying units (22 ') comprises a first cooling device (12 ') configured to cool the compressed air to a positive temperature of a few degrees above zero and close to freezing temperature and a first freezing device (14 ') disposed downstream of the first cooling device (12 ') and configured to cool the compressed air to a sufficiently negative value, a second one of the drying units (22 ") comprises a second cooling device (12") and a second freezing device (14 "), each of the freezing devices (14 ', 14") having a first freezing operating state and a second defrosting operating state,
wherein it provides the following further steps:
-passing the air leaving the first cooling device (14 ') in the opposite direction in the first cooling device (12 ') and/or the second cooling device (12 ") so as to cause a temperature drop of the air entering the first cooling device (12 ') and/or entering the second cooling device (12");
-passing the air leaving the second cooling device (14 ") in the opposite direction in the second cooling device (12") and/or the first cooling device (12 ') so as to cause a temperature drop of the air entering the second cooling device (12 ") and/or entering the first cooling device (12');
-actuating the valve means (27', 27 ") between at least one first operating condition and a second operating condition:
in the first operating state, the incoming compressed air flow is first conveyed through the first cooling device (12 ') and the first freezing device (14') placed in the defrosting operating state and then through the second cooling device (12 ") and the second freezing device (14") placed in its freezing state;
in the second operating state, the incoming compressed air flow is first conveyed through the second cooling device (12 ') and the second refrigerating device (14') placed in its defrosting operating state and then through the first cooling device (12 ') and the first refrigerating device (14') placed in its refrigerating state,
wherein the flow of compressed air is conveyed through at least one deflecting element (123 a, 123 b) downstream of the respective freezing devices (14 ', 14 ") of the first drying unit (22 ') and/or of the second drying unit (22"), said deflecting element (123 a, 123 b) being selectively activatable in order to choke the passage of the compressed air into one and/or the other cooling device (12 ', 12 "),
wherein the deflecting element (123 a, 123 b) has a first inactive condition, in which it allows the entire air flow exiting one freezing device (14 ', 14 ") to enter the respective cooling device (12 ', 12") of the same drying unit (22 ', 22 ") in order to perform a heat exchange with the entering air flow, a second active condition and a third active condition; in the second start-up state it diverts the entire air flow leaving one freezing device (14 ', 14 ") into the cooling device (12", 12 ') of the other drying unit (22 ', 22 "); in the third start-up state it is in an intermediate position, so that part of the air flow leaving one freezing device (14 ', 14 ") is diverted into the corresponding cooling device (12 ', 12") of the same drying unit (22 ', 22 ") and part of the air flow is diverted into the cooling device (12", 12 ') of the other drying unit (22 ', 22 ").
5. Drying method according to claim 4, characterised in that it provides for freezing the air alternately using at least two different air-refrigerant exchangers (20 ', 20 ") of the freezing device (14 ', 14"), and in that, after the air is cooled and before it is frozen, the method makes it pass through an evaporator (38) in order to maintain the temperature at the inlet of one or the other of the air-refrigerant exchangers (20 ', 20 ") constant.
6. Drying method according to claim 4 or 5, characterised in that defrosting of the ice formed in the freezing apparatus (14 ', 14 ") is effected by causing a portion of the drying air leaving the dryer (10) to flow in the freezing apparatus (14 ', 14") by means of a cyclic or continuous activation of at least one condensation drain (17) connected to the freezing apparatus (14 ', 14 ").
7. Drying method according to any of claims 4 to 5, characterized in that defrosting of the ice formed in the freezing apparatus (14', 14 ") is achieved by introducing compressed humid air into the dryer (10) by means of the air inlet (11).
8. Drying method according to claim 6, characterised in that defrosting of the ice formed in the freezer device (14', 14 ") is effected by introducing compressed humid air into the dryer (10) by means of the air inlet (11).
9. Drying method according to any of claims 4 to 5, characterized in that defrosting of the ice formed in the freezing apparatus (14', 14 ") is achieved by introducing a flow of hot gas by means of at least one valve (33) of the cooling unit (28).
10. Drying method according to claim 6, characterised in that defrosting of the ice formed in the freezing apparatus (14', 14 ") is effected by introducing a flow of hot gas by means of at least one valve (33) of the cooling unit (28).
11. Drying method according to claim 7, characterised in that defrosting of the ice formed in the freezing apparatus (14', 14 ") is effected by introducing a flow of hot gas by means of at least one valve (33) of the cooling unit (28).
12. Drying method according to claim 8, characterised in that defrosting of the ice formed in the freezing apparatus (14', 14 ") is effected by introducing a flow of hot gas by means of at least one valve (33) of the cooling unit (28).
Applications Claiming Priority (3)
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|---|---|---|---|
| ITUD20140089 | 2014-05-29 | ||
| ITUD2014A000089 | 2014-05-29 | ||
| PCT/IB2015/052616 WO2015181652A1 (en) | 2014-05-29 | 2015-04-10 | Cooling dryer for compressed air and corresponding method |
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| Publication Number | Publication Date |
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| CN106714937A CN106714937A (en) | 2017-05-24 |
| CN106714937B true CN106714937B (en) | 2020-05-19 |
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| CN201580035524.7A Active CN106714937B (en) | 2014-05-29 | 2015-04-10 | Cooling dryer for compressed air and corresponding method |
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| US (1) | US10724750B2 (en) |
| EP (1) | EP3148677B1 (en) |
| CN (1) | CN106714937B (en) |
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| CN108444312A (en) * | 2018-03-23 | 2018-08-24 | 轻工业环境保护研究所 | A kind of dry air closed circulation device |
| US11071929B2 (en) | 2018-06-19 | 2021-07-27 | Ingersoll-Rand Industrial U.S., Inc. | Gas-water separation system and methods |
| CN109260908A (en) * | 2018-09-30 | 2019-01-25 | 深圳市贝腾科技有限公司 | Dry filtrating equipment |
| CN110201499A (en) * | 2018-11-06 | 2019-09-06 | 深圳市贝腾科技有限公司 | Heat-exchange device and freeze drier |
| US11369920B2 (en) | 2019-12-31 | 2022-06-28 | Ingersoll-Rand Industrial U.S., Inc. | Multi-mode air drying system |
| DE102020210532B3 (en) * | 2020-08-19 | 2021-07-29 | Thyssenkrupp Ag | Compact recirculation area of a recirculation fuel cell device |
| US20220107133A1 (en) * | 2020-10-05 | 2022-04-07 | Ingersoll-Rand Industrial U.S., Inc. | Multi-unit compressed air drying system |
| US11918954B2 (en) * | 2020-12-30 | 2024-03-05 | Ingersoll-Rand Industrial U.S., Inc. | Systems and methods for single header glycol distribution for multiplexed heat exchangers |
| US20220288517A1 (en) * | 2021-03-11 | 2022-09-15 | JAPAN AIR DRYER SALE Co., Ltd. | Condensation device for compressed air |
| US11648508B2 (en) | 2021-03-15 | 2023-05-16 | Ingersoll-Rand Industrial U.S., Inc. | Systems and methods for sequencing operation of compressed air dryers |
| CN113432447A (en) * | 2021-06-17 | 2021-09-24 | 上海深城环保设备工程有限公司 | Cooling and dehumidifying heat exchanger |
| US11940198B2 (en) * | 2021-12-01 | 2024-03-26 | Lineage Logistics, LLC | Automated blast cell loading and unloading |
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| JPH0689951B2 (en) | 1988-07-28 | 1994-11-14 | 株式会社日本メディックス | Air dehumidification cooling device |
| US5119640A (en) | 1990-10-22 | 1992-06-09 | Conrad Richard H | Freeze-thaw air dryer |
| US5428963A (en) | 1994-05-12 | 1995-07-04 | Korycki; Leszek S. | Compressed air system to deliver dry and clean air |
| AT402026B (en) * | 1994-09-29 | 1997-01-27 | Gossler Ewald | METHOD AND DEVICE FOR COOLING GASES |
| US5664426A (en) * | 1996-02-09 | 1997-09-09 | Pai | Regenerative gas dehydrator |
| US6712885B1 (en) * | 2002-09-05 | 2004-03-30 | Pioneer Air Systems, Inc. | Siloxane removal system |
| BE1015186A3 (en) * | 2002-11-18 | 2004-10-05 | Atlas Copco Airpower Nv | Device for simultaneous cooling and removing moisture from a gas from a compressor. |
| US6968712B2 (en) * | 2003-04-02 | 2005-11-29 | Ken Wilkinson | Pressurized air chamber in a main freezer for flash freezing |
| CN201342314Y (en) * | 2008-12-11 | 2009-11-11 | 攀枝花新钢钒股份有限公司 | Compressed air loss-less afterheat drying regenerative device |
| US9459029B2 (en) * | 2009-01-19 | 2016-10-04 | Fujikoki Corporation | Valve controller, valve controlling method, refrigeration and cold storage system, device and method for controlling the system |
| CN101839653A (en) * | 2009-03-19 | 2010-09-22 | 上海超滤压缩机净化设备有限公司 | High-temperature air-cooling refrigerating type compressed air dryer using combined heat exchanger |
| WO2012023949A1 (en) | 2010-08-20 | 2012-02-23 | Carol Diane Krumbholz | Vapor recovery system utilizing compression-condensation processes and related methods |
| CN203342632U (en) * | 2013-06-18 | 2013-12-18 | 东莞理工学院 | Combined compressed air cryogenic dehumidifier |
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- 2015-04-10 WO PCT/IB2015/052616 patent/WO2015181652A1/en active Application Filing
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| US20170074528A1 (en) | 2017-03-16 |
| CN106714937A (en) | 2017-05-24 |
| EP3148677A1 (en) | 2017-04-05 |
| WO2015181652A1 (en) | 2015-12-03 |
| US10724750B2 (en) | 2020-07-28 |
| EP3148677B1 (en) | 2018-06-06 |
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